Apparatus for constructing building structures

ABSTRACT

A method and apparatus for constructing building structures of various desired geometric patterns comprising the steps of establishing a mold controllable in successive steps along a path corresponding to the desired geometric pattern, the mold having a surface shape corresponding to a segment of the desired geometric pattern; applying a building construction material in liquid or atomized form in abutment with said surface to which said building material solidifies to establish a segment of the building structure; temporarily retaining said mold in abutment with the applied construction material to support the applied construction material for a time period sufficient to permit said applied material to solidify sufficiently to be self sustaining; and repositioning the mold in successive positions along the geometric pattern and adjacent to a previously cured segment and applying said building material in abutment with said mold at each position.

United States Patent [1 1 Casey 1 Oct. 23, 1973 APPARATUS FOR CONSTRUCTING BUILDING STRUCTURES Robert J. Casey, 1959 Ashland Way, San Jose, Calif. 95130 22 Filed: Oct. 8, 1971 21 Appl. No.: 187,806

[76] Inventor:

[52] US. Cl 425/4, 425/60, 425/64, 264/33, 264/309, 264/DIG. 72 [51] Int. Cl B29d 27/02 [58] Field of Search 425/60, 63, 4, DIG. 121, 425/64; 249/114, 115; 264/33, 309, D10. 72

[56] References Cited UNITED STATES PATENTS 2,607,100 8/1952 Urschel 425/60 2,877,530 3/1959 Winn, Jr. 425/60 3,417,429 12/1968 Wright 425/60 3,548,453 12/1970 Gavis 425/60 2,187,223 1/1940 Cory 264/33 3,016,595 1/1962 Durst 264/33 X 3,139,464 6/1964 Bird et al. 264/33 X 3,195,208 7/1965 Winn, Jr. 425/63 3,245,648 4/1966 Johansson et al 264/33 X 3,659,977 5/1972 Haws 425/63 X Primary Examiner-Robert L. Spicer, Jr.

Att0rney--Thomas E. Schatzel [5 7] ABSTRACT A method and apparatus for constructing building structures of various desired geometric patterns comprising the steps of establishing a mold controllable in successive steps along a path corresponding to the desired geometric pattern, the mold having a surface shape corresponding to a segment of the desired geometric pattern; applying a building construction material in liquid or atomized form in abutment with said surface to which said building material solidifies to establish a segment of the building structure; temporarily retaining said mold in abutment with the applied construction material to support the applied construction material for a time period sufficient to permit said applied material to solidify sufficiently to be self sustaining; and repositioning the mold in successive positions along the geometric pattern and adjacent to a previously cured segment and applying said building material in abutment with said mold at each position.

13 Claims, 22 Drawing Figures PATENTEDUU 23 ms SHEEI lUF 6 SIB INVENTOR. ROBERT J. CASEY FIG. I B

VAT

SIB

ATTORNEY PATENTEBUUZS mu SHEET 3 BF 6 IOOA 1 I008 q.

INVENTOR.

ROBERT J. CASEY ATTORNEY PATENTEDUBI 23 I973 SHEET t 0F 6 FIG.8I

INVENTOR. ROBERT J- CASEY FIG.3

ATTORN EY APPARATUS FOR CONSTRUCTING BUILDING STRUCTURES BACKGROUND OF THE INVENTION The present invention relates to a method and apparatus for the construction of monolithic building structures and stressed skin monlithic building structures. Continuous efforts are being expended to provide structural, economical, functional and aesthetic improvements in dwelling, commerical and industrial building structures. Construction times for building structures using prefabricated components are relatively lengthy and costly. The merits of liquid or atomized materials which solidify and expand in volume upon application are presently recognized in the construction of prefabricated building modules and in the construction of monolithic structures having varying proportions of circular or spheroidal shape. The partial preassembly of modular construction interposes an additional series of factory operations to the construction cycle. The present methods of monlithic construction vwith these materials are not generally capable of producing wide variety of geometric shapes; they are not sufficiently flexible in the accommodation of architectural detail or in the integral molding of interior partition walls, window and door openings and the like; and they do not provide for the incorporation of integrally bonded surface reinforcing skins.

The present invention provides a relatively economical system of modular and reusable tooling for the construction of building and introduces a mobile factory concept for producing monolithic building structures with precise dimensional control in various geometric shapes or combination of shapes. Conventional structural and/or decorative surface materials may also be used in conjunction with the foam. High density foams or other materials may be applied to the interior and exterior surfaces to impart additional structural strength and hard surfaces.

SUMMARY OF THE PRESENT INVENTION The present invention relates to a method and apparatus for the construction of building structures utilizing fluid construction materials such as polyurethane foam as the principal structural material. The construction material may be applied to molds to establish individual building segments. The molds are successively repositioned along a select geometric path and while in position provide for the establishment of a bay segment of the building structure. The bay segments are constructed to be integral with a previously formed bay segment to establish a unitary building structure. The invention provides for simplified and inexpensive construction of monolithic structures at the building site. The structures may be produced responsive to controlled positioning of the mold in successive steps. The path of the mold or/and the shape of the mold may be varied to provide various geometric shapes or combination of shapes to permit wide versatility in structural designs. The invention permits wide versatility in the incorporation of other materials to provide windows, doors, utilities, etc., as customarily incorporated in building structures. Conventional structural and/or decorative surface materials may be used in conjunction with the structural material. Structural surface materials may be in the form ofjoined segments or may be applied in a continuous thick film to produce a relatively high strength skin on one or both surfaces of the basic building material to produce a monolithic stressed skin structure. Partition walls, ceilings, window frames, door frames, and so forth, may be molded in place as integral parts of the structure utilizing the same construction material or other materials. Plumbing, heating, electricity and other utility supplies and materials may be provided for and molded in as an integral part of the structure.

The present invention permits the exploitation of the characteristics of urethane foam materials and the like. Said materials are of light weight and have the ability to be applied to a mold surface or mold cavity through a hose fed dispensing gun and upon application to expand its original volume many times in the formation of foam. The mold may be selected of a size to permit it to be readily transported to the building site and manipulated about. The foam, once applied to the mold, solidifies rapidly and bonds to itself and other material. The mold surface, which is selected of a material to be nonadhering to the construction material, is moved in successive controlled steps along a path corresponding to the desired geometric pattern. The mold is progressively moved along the given path as the applied foam BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partially-sectioned,perspective view of a building constructed in accord with the teachings of the present invention;

FIG. 1A and 1B illustrate in perspective a section of a formed segment of the structure of FIG. 1 in combination with a mold and foam applicator in accord with the teachings of the present invention;

FIG. lC-lF illustrate the successive steps taken in the process of constructing the structure of FIG. 1;

FIGS. 2A-2H illustrate a plurality of alternative molds for the constructing of a building structure in accord with the teachings of the present invention;

FIG. 3 illustrates an embodiment of a mold adapted to establish a structural and decorative skin;

FIG. 4 illustrates an embodiment of a mold apparatus to establish a ceiling of building structure in accord with the teachings of the present invention;

FIGS. 5A and 5B illustrate alternative embodiments of double molds for establishing building structures in accord with the teachings of the present invention;

FIG. 6 illustrates an embodiment of a mold apparatus to establish perimeter and partition walls of a building structure in accord with the teachings of the present invention;

FIG. 7 illustrates an embodiment of a mold apparatus to establish partition walls with skins of a building structure in accord with the teachings of the present invention; and

FIG. 8 illustrates an embodiment of a mold apparatus to establish a ceiling or roof structure.

DESCRIPTION OF PREFERRED EMBODIMENTS FIG. 1 depicts, in perspective, a building structure referred to by the general reference character 1 constructed in accord with the teachings of the present invention. The structure 1 is constructed of a construction material in the form of solidified urethane foam 2. The urethane is a two component system and reacts upon being mixed in the liquid or atomized state. The

use of urethane provides for light weight; the ability to be applied to a surface or cavity through a hose fed dispensing gun; upon application, the immediate ability to increase volume substantially over its original volume in the formation of foam; the ability to solidify in seconds after foaming; and the ability to bond to itself and to other materials. The construction material 2 is adapted for transport to the construction site in vats and in the form of chemically reacting liquids which liquids are mutually introduced at a dispensing gun to initiate the foaming and solidifying action for application.

The illustrated structure 1 includes a pair of arcuate side walls 3 and 5 ofa radius R, and a pair of planar end walls 7 and 9 to form the enclosed structure. The side wall 5 carries a window structure 11 projecting therefrom with the window supported vertically. The end wall 7 includes a sliding door structure 13. The end wall 9 is shown as having a door 15 and a window 17. The building structure 1 includes electrical utilities 19 and 21 which are an integral part of the structure providing interior electrical outlets and which are adapted to engage an exterior electricity supply source. The unit 1 further includes plumbing utilities 23 and sewage utilities 25 extending from the exterior to the interior. To partition the interior, the building 1 includes interior partition walls 27 and 29.

- FIG. 1A illustrates in perspective a bay segment A1 of the building 1 establishing part of the side wall 3 end wall 9 corner and constructed in accord with the teaching of the present invention. Construction supplies include a molding apparatus referred to by the general reference character 31. As hereinafter described, the molding apparatus 31 is adapted to be guided and controlled in incremental steps both laterally and radially along a path corresponding to the desired geometric path of the proposed building structure 1 during the construction operation. The molding apparatus 31 includes a pair of guide tracks 33 and 34 extending parallel to one another and longitudinally over a base 35 illustrated in the form of a rectangular flooring platform which becomes an integral part of the building structure 1. The base member 35 may assume any of various shapes and establishes the base over which the wallsof the structure are to be established. The guide track 33 is engaged to a pair of elongated arms 36 and 37 respectfully by means of a pair of mounted pivots 39 and 41. As illustrated, the arms 36 and 37 are joined to the track 33 such that the arms 36 and 37 may rotate about the pivots 39 and 41 to establish an arcuate path. About the other terminal end of the elongated arms 36 and 37 is a mold member 43. The mold member 43 has an exterior front face 45 shaped of a desired pattern in accord with the desired geometric pattern of the side walls 3 and 5 of the building 1 to be formed such that when rotated, the path of the mold face coincides with the desired geometric shape of the side wall 3. Referring to FIG. 1, the exterior shape of the side walls 3 and 5 of the building is arcuate having a radius R and accordingly, the exterior shape of the front surface 45 of the mold member 43 is arcuate of a radius R to correspond to the shape of the side walls 3 and 5 of the desired building. The molding face 45 includes a surface coating which is nonadherent to the building material 2 to be utilized. The mold member 43 further includes a lateral side member 46 having a planar surface to establish a mold for the end walls 7 and 9 which as illustrated in FIG. 1 are planar and normal to the side walls 3 and 5. The side member 46 is disengageable from the mold 43 and may be engaged on either lateral side of the front face 45. Accordingly, the mold face 45 and mold member 46 may be guided in successive steps along a path duplicating the desired shape of the building 1. As hereinafter described, with the side member 46 position as illustrated in FIGS. 1A and 13, it serves as a mold to establish a portion of the end wall 9 integral with the side wall 3 and when positioned on the opposite side of the front face 45 it serves as a mold to establish the end wall 9 integral with the side wall 5. Thus, with the mold 46 in place, the mold apparatus 31 is adapted to duplicate two different segments of the building structure 1, namely an end wall and a side wall. The radius R is capable of being lessened to retract the mold face 45 from contact with the solidified foam to permit relocation of the mold 43. The ability to retract is provided by a pair of removable wedges 47A and 47B which engage the track 33 and lock the pivots 39 and 41 in position. The removability of the wedges 47A and 478 permits the retraction of the pivots 39, 41 and the tool assembly 31.

As illustrated in FIGS. 1A and 18, with the mold members 43 and 46 in place, the urethane material is applied to establish a segment bay A1 of the building 1 forming the base corner of the walls 3 and 9. Prior to application of the building material 2, the door framing 15 may be supported in place by engagement to the base support 35. The mold member 46 is positioned on the interior of the door framing 15 such that the building wall structure 9 may be established integral with said framing. The urethane building material is applied by means of a dispensing gun 48 engaged to a pair of hoses 49A and 498 in turn joined to a pump 50 to pump liquid urethane from a pair of vats 51A and 518. The liquid urethane is atomized and dispensed by spraying the foam against the surfaces 45 and 46 in a series of layers to build up the desired thickness. The sprayed foam solidifies against the mold facings and becomes self sustaining. Once the bay segment of the material 2 becomes self sustaining the mold may be retracted and repositioned to form another bay segment. The spraying operation of the urethane foam is repeated. The sprayed urethane foam bonds to foam sprayed at previous positions to form monolithic shell structure.

FIGS. 1C1F illustrate side, front and rear views of the structure of FIG. 1 and illustrate diagrammatically the various steps which may be taken to construct the walls 3, 5, 7 and 9 of the building of FIG. 1. FIG. 1C is a side view of the wall 3 while FIG. IE is a side view of the wall 5. FIG.1D is an end view of the back wall 9 and FIG. 1F is an end view of the front wall 7. As illustrated in FIGS. 1A, 1B and 1C, the molding apparatus 31 is first positioned in place in Position (1) to mold the bay segment A1 which constitutes a segment of the side wall 3 and the back wall 9. The casing of the door 15 is supported in place on the base 35. The molding member 43 is positioned in place and the constructing material is applied by means of the hose fed dispensing gun 48 joined to the hoses 49A and 49B extending to the pump 50 pumping the liquid construction material from the vats 51A and 5113. An operator handles the gun and sprays several coats of the constructing material over the mold face surfaces 45 and 46 and about the door framing until the segment A1 is created of desired thickness. The construction material, when ap-' plied assumes a foam characteristic and a substantially increased volume over that relative to its volume in the liquid state within the vats 51A and 518. After the applied material of segment A] sufficiently solidifies to be self-sustaining, the mold 43 is retracted, and then rotated about its pivot points 39 and 41 to Position (2) and retained in that position. I

In Position (2), the operator again applies the constructing material to establish the segment bay B1 which adheres to the segment bay A1. The segment bay A1 and B1 becomes integral. Accordingly, the bay B1 forms a section of the side wall 3 and a section of the end wall 9 about the door 15. After the bay B1 is built up to the desired depth and solidifies sufficiently to be self-sustaining with the bay Al, the mold 43 is rotated further to Position (3). In Position (3) the constructing material is sprayed against the side mold panel 46 to establish the bay C1 and to further extend the structure of side wall 3 and end wall 9. Once the bay C1 is built up to sufficient thickness and solidified sufficiently to be self-sustaining with the bays B1 and Al, the mold is rotated on to Position (4). In Position (4) the bay D1 is established with the casing 17 held in place.

Referring now to FIGS. 18 and 1C it may be noted that the wedges 47A and 478 may be withdrawn and the mold apparatus 31 shifted to the track 34 such that the mold 43 is in position to establish segments of wall 5 and complete the end wall 9. Accordingly, with the apparatus 31 on track 34 the molds 43 and 46 are placed in Position (5)(see FIG. IE) to establish the bay segment A5 constituting a segment of the wall 5 and the end wall 9. Again, the constructing material 2 is sprayed in abutment with the surfaces 45 and 46 to the desired thickness, encasing the lower portion of door frame 15 and encompassing the plumbing piping 23 and sewage piping 25. When bay segment A5 sufficiently solidifies the mold 43 is pivoted to Position (6) the window casing 11 is supported vertically and supported thereon as hereinafter described in further detail and illustrated by FIG. 2E. The window 17 is similarly supported on mold face 46. The operator sprays the constructing material on the molding surfaces and around the window casings 11 and 17. The constructing material solidifies and adheres to establish the bay segment B5 to integrally include the window casing 11, a portion of window casing 17 and door frame 15. Once the constructing material 2 of bay segment B5 sufficiently solidifies and becomes self-supporting the mold 43 is rotated further to Position (7) and the bay segment C5 is established integral with bay segment B5 completing the encasement of window 17 and further encasing the door frame 15. The mold apparatus 31 is next rotated to Position (8) to establish bay segment D5. Bay segment D5 completes the end wall 9 and closes the top of the structure by integrally spraying the construction material 2 of bay segment D5 with the upper edge of the bay segment D1.

The wedges 47A and 47B are removed and the mold 43 urged laterally along the track 34. The side mold wall 46 is removed if desired and the mold face 45 is placed in Position (9) to establish the bay segment A6 of the side wall 5 (see FIG. 1E). The constructing material 2 is applied to the mold surface 45 to establish the bay segment A6 integral with the base 35 and the bay segment A5. The mold 43 is successively positioned in Positions (10), (11) and (12) to establish the bay segments B6, C6 and D6.

The mold 43 is then repositioned on the track 33. The mold 43 is then placed with the mold face 45 in P0- sition (13) to establish the bay segment A2 integral with the base 35 and the bay segment Al. The mold 43 is successively repositioned in Positions (14), (15) and (16) to establish the bay segments B2, C2 and D2 of the wall 3 and further enclosing the structure 1. The mold apparatus 31 is then urged laterally along the track 33 and the mold face 45 placed in Position (17) to establish the segment bay A3 integral with the segment A2. The mold is successively positioned in Positions (18), (19) and (20) to establish bay segments B3, C3 and D3.

Next the overhang of the side wall 3 is established. To do so, the mold 43 is moved laterally along the track 33 and set at Position (21) overhanging the front edge of the base foundation 35 a sufficient distance to allow a fence 51 to be clamped to the face 45 of the mold 43 at an angle (1) as illustrated in FIG. 1C. The segment bay A4 is established in Position (21) integral with segment bay A3. The mold 43 is then rotated to Position (22) with the fence 51 in place and the segment bay B4 is sprayed to the desired depth. The process is continued in successive Positions (23) and (24) to establish the segment bays C4 and D4. The fence 51 is removed and the mold 43 is repositioned on the track 33 and placed in Position (25) to establish bay A7. The mold 43 is then successively repositioned in Positions (26), (27) and (28) to establish bay segments B7, C7 and D7 (see FIG. 1B). The mold 43 is then moved to Position (29) and the fence 5] is again secured to the mold surface 45 at the angle (1) to establish bay segment A8. The mold 43 is then successively rotated to Positions (30), (31) and (32) with the fence 51 clamped in place to establish bay segments B8, C8 and D8 to complete the roof overhang of the side wall 5. The fence 51 is then removed and the mold 43 returned to Position (25).

The side mold 46 is repositioned in attachment to mold face 45 at Position (33) (see FIG. 1F). The door frame 13 is positioned in place constructing material is sprayed against the mold 46 and bay segment A9 is established with the constructing material encasing the lower portion of the door frame 15. The mold 43 is rotated to place the mold 46 successively in Positions (34), (35) and (36) to establish bay segments B9, C9 and D9 encasing the remainder of one side and most of the top of door frame 15. The mold 43 is then repositioned to the track 33 and in position (37) coinciding with Position (17). The mold 46 is repositioned in attachment to the mold 43 at Position (37) establishing bay segment A10 of the end wall 7. The mold 43 is rotated to place the mold 46 successively in Positions (38), (39) and (40) to establish bay segments B10, C10 and D10 completing the closure of end wall 7 with the door casing 13 integral therewith. The mold 43 is then disengaged from the track 33 and removed from the interior.

Building structures commonly require numerous different configurations and frequently it is desireable to include paneling or other skin surfaces over the primary structure to provide aesthetic or/and structural improvements. Commonly it is also desireable that the interior or/and exterior wall have unique designs. FIGS. 2A-2H inclusive, depict various different structures of mold appparatus which may be utilized for constructing building structures in accordance with the teachings of the present invention. The various molds may be interchangeably mounted to any of various mold support structure combinations. FIG. 2A shows a side view of a unitary mold apparatus 60 designed for controlling the dimensions and surface finish on the exterior surface of a building structure. As shown the molding apparatus has a mold 61 with a surface facing 62. The mold 61 is engaged to an elongated arm 66 adapted to rotate about a pivot point 64. The arm 66 is joined to the facing 62 by means of an interconnect 68 to establish a unitary molding. Accordingly, an operator sprays the face 62 of the mold 61 to establish the solidified construction material 2 with the exterior surface assuming the pattern of the face 62.

FIG. 2B shows a side view of a molding apparatus 70 similar to that of FIG. 1 and carrying the same reference numerals distinguished by a prime designation. In FIG. 28 a structural and/or decorative skin 71 is positioned in abutment with the face 45 of the mold and sprayed with the constructing material. The skin 71, which may be in the form of a flexible plywood, then becomes an integral portion of the building structure by the bonding action of the constructing material 2 to the skin. The skin 71 may serve an aesthetic function and/or to reinforce the wall structure and provide a stressed skin monolithic structure. Abutting skin segments 71 may be adhesively or mechanically joined by batten strips to establish a continuous structural skin on the entire surface of the geometric shape.

FIG. 2C shows a molding structure 73 incorporating both an interior and exterior mold 75 and 77, respectively, joined to an arm 78. The molds 75 and 77 respectively carry mold surfaces 79 and 80 adapted to control the dimensions and finish on both the internal and external faces of a segment bay 81 of the constructing material 2. The constructing material 2 is applied through the use of the gun 47 through a top opening intermediate the molds 75 and 77. Surface skins (not shown) may be used with the mold of FIG. 2C on the interior and/or exterior face similar to that of FIG. 28. FIG. 2C illustrates a further feature in which a skin 82 is sprayed to the exterior surface of the segment bay 81 to reinforce the structure. The skin 82 may be comprised of a high density foam or be in the form of glass reinforced resin, etc. to establish a structural skin and hard surface.

FIG. 2D shows a further embodiment of a mold, adapted to include buttresses on the face of the mold surface. As illustrated, a mold structure 83 similar to the mold structure 31 may be included to carry a pair of buttresses 84 and 85 on a surface 86 of an arcuate mold 87. The buttresses 84 and 85 provide aesthetic and structural improvements to the resultant molded bay segments of the building structure as illustrated by a bay segment 88.

FIG. 2E shows a section of the molding structure 31 with a window frame 89 spray foamed into place by the use of secondary mold pieces 90, 91 and 92 attached to the face 45 of the mold 43 so as to provide a vertical window framing similar to the window 11 in the building 1 of FIG. 1 as illustrated in FIGS. 1, 1C, 1D and IF. As shown in FIG. 2E the window framing 89 may be suspended along the molding surface 45 of the mold 43 and held in position by means of the pieces 90, 91 and 92. The piece 92 provides a top longitudinal spacer and the pieces 90 and 91 provide a pair of side spacers to suspend the window casing 89 laterally from the mold surface 45 and vertical relative to the basefoundation of the building. The pieces and 91 have three edges with an arcuate edge of a radius coinciding with the radius of the surface 45", a top edge and a vertical edge normal to the top edge. The constructing material 2 may be sprayed onto the surface of the molds 43, 90, 91 and 92 about the window casing 89. The constructing material 2 adheres to the casing 89 and supports it in place. After the bay segment is sprayed to the desired depth and the constructing material 2 solidifies sufficiently to be self supporting, the mold 43 is rotated. The secondary molds comprising the pieces 90, 91 and 92 may be removed, or in the alternative, the molding pieces 90, 91 and 92 may be left in place as a permanent part of the building structure.

FIG. 2F shows an alternative embodiment of the molding apparatus of the present invention, referred to by the general reference character 93. The apparatus 93 is similar to the mold 31 in various aspects and for similar components carries the same reference numeral distinguished by a triple prime designation. The mold apparatus 93 supports thereon skin material dispenser in the form of a roll structure 94 carrying a supply of flexible plyable skin material 95 which may be in the form of a cloth or other flexible material to provide an adherent continuous skin about the interior surface of a resultant bay 96 of the constructing material. Accordingly, the cloth material 95 may be dispensed and released from the roll structure 94 and positioned over the face 45 of the mold 43 continuously as the mold 43 is repositioned and the constructing material applied 2. As 'the mold 43 is repositioned and the constructing material applied 2, the skin material 95 is unrolled from the structure 94 to establish an interior skin on the resultant bay and building structure. The roll 94 may also be utilized in combination with molds having both interior and exterior walls such as FIG. 2C or with molds having exterior walls as in FIG. 2A.

FIG. 2G shows a further embodiment of the present invention, referred to by the general reference character 97 in which a rectangular mold support apparatus 98 supports a configured mold surface 99 which is capable of being moved laterally to successive positions along a pair of guide members 100A and 1008 to produce a series of integrally connected bays. The support 98 may be moved along the tracks 100A and 1008 by a set of wheels 101A and 1013. In this embodiment the mold support structure 98 need not rotate upwardly around a pivot point in the generation of a bay segment 102 of desired surface configuration.

FIG. 2H illustrates a further embodiment, referred to by the general reference character 103, including a configured mold surface 104 supported by a mold support structure 105. The support structure 105 carries a wheel 106 about one end and is engaged to a sleeve 107 pivotable about a fixed vertical support 108 such that the structure 103 is pivotable about said support 108to establish a series of integrally connected vertical arcuate bays 109 in the construction of circular segments of building structures.

FIG. 3 illustrates a mold, referred to by the general reference character 110, adapted to establish a planar three-dimensional decorative panel 111 of the constructing material 2. The mold 110 of FIG. 3 has a three-dimensional designed face 112. In FIG. 3 the mold 110 is shown as being rotated approximately 90 out of position relative to the resultant bay 111 to illustrate the mold face 112 relative to the finished bay design utilizing the mold 110. The mold 1l0 is adapted to provide a uniform design and is divided into sections A and B as illustrated in columns of uniform configuration such that in constructing bay segments the columns of a bay segment may overlap with a column of the mold. The finished bay segment section 111 diagrammatically illustrates the position of the mold 110 laterally for establishing the segment 111. First in position 1, the mold 110 establishes a bay segment having both columns A and B to establish two integral columns I and II. Then the mold 110 may be moved laterally to position no. 2 such that there is an overlap of column A of the mold and column II of the bay segment. In position 2, the mold 110 provides alignment of column B with the previously formed columns I and II of the bay segment 111 such that a third column III is in proper alignment and position relative to column II. The constructing material may be applied to establish column III. The mold 110 may then be positioned laterally in position 3 to establish the column IV in which case the column A of the mold is interengaged with the column III of the bay segment 111. This process may be repeated in successive steps laterally and vertically to establish a monolithic wall of uniform design. FIG. 3 further illustrates that the mold 110 itself may be established from the same constructing material as the building structure. To establish the mold 110, a pattern may be established on a base 113 by spraying the constructing material to the base 113 and then establishing the desired pattern on the exposed surface. The exposed surface is then coated with a skin 115 which when cured does not adhere to atomized constructing material. Alternatively the patterned mold surface 113 may be utilized to support similarly patterned panels of decorative material having a surface to which the constructing material of the structure will adhere. The decorative panels then remain permanently bonded in place as a surface of the structure.

FIG. 4 shows a further embodiment of molding apparatus, referred to by the general reference character 114 in which vaulted ceilings or roof bays are constructed. The molding apparatus structure 114 includes a guide track means 115 supported on a base 116. An adjustment arm 117 having a telescopic section 118 extends vertically from a support platform 119 movable along the track 115. A mold 120 with a face 121 carries a skin member 122 in place and the constructing material 2' is sprayed thereon to establish the ceiling. The skin member 122 may be removed or retained in'position. As illustrated the skin member 122 is retained in position to make part of ceiling bay segment 123. Adjacent skin members are joined by a batten strip 124. During construction of the ceiling, adjacent bays and member 117 are joined together by the batten strip 118. The batten strip 118 is put in place as each new bay is constructed. The constructing material, as it cures, adheres to the batten strip 118 and to the skin member 117 to secure members in inherent position.

The present invention may further utilize controllable molds to control both the internal and external surfaces of a structure. This concept provides further control of thickness and control of texture on both surfaces. Spaced double molds fitted with lateral fence assessories establish an open top cavity thereby permitting the constructing material to be applied by pouring or spraying. In some environments, pouring is less effected by ambient weather conditions. FIG. 5A illustrates the top view of apparatus, referred to by the general reference character 150, utilizing dual molds in whichthe spacing between the dual molds may be adjusted and controlled. In FIG. 5A an outer mold 152 is supported by and positioned laterally in relationship to an interior or main mold 154. The molds 152 and 154 are both supported by an elongated arm 156 with the positioning between the molds 152 and 154 being adjustable along the elongated arm member 156. The arm member 156 is in turn engaged to a guide track 157 about which the arm 156 may be rotated and guided laterally. The arm member 156 carries a number of apertures 158 adapted to receive securing fasteners 160 in the form of pins. The interior mold 152 and exterior mold 154 are slidable along the elongated arm respectfully by means of support brackets 162 and 164 each carry apertures for alignment with apertures 158 in the elongated arm 156. The fastener pins 160 may be inserted when the interior and exterior molds 152 and 154 are in the desired positions. With the molds 152 and 154 in desired position, the constructing material 2 may be applied through the top surface. The molds may carry a fence member 166 about one lateral end so as to provide an enclosed area to facilitate pouring of the constructing material. As the molds 152 and 154 are positioned to establish abutting bays 168 and 170, the open lateral end of the molds may overlap the previously constructed bays.

FIG. 5B shows an alternative embodiment of a mounting double mold apparatus, referred to by the general reference character 170, in which an exterior mold 172 with a surface 173 is mounted on a boom assembly 174. An interior mold apparatus 176 may include a mold 178 with a face 180. The mold 178 is secured to an elongated arm 182 adapted to rotate and be guided laterally. The exterior mold 172 may be mounted on a spring loaded pivot arm 184 attached to a work platform 186. The spacing between the interior mold surface and the exterior mold surface 173 may be controlled by means of a fence 188 similar to the fence 166 of FIG. 5A and by the overlap of the mold 172 on the previously constructed bay segments. Spring pressure is applied to hold the mold 172 in position by control of the boom 174. The constructing material 2 may be poured or sprayed within the interior of the two molds 172 and 178. I 1

FIG. 6 illustrates a further embodiment of molding apparatus referred to by the general reference character 200 and utilizing double molds in the construction of vertical wall 201. The apparatus 200 includes an" inner mold 203 of a size convenient to support a standard building surfacing panel 204 of plywood or other skin material. The mold 203 is attached to support structure having castored wheels 206 joined to a platform 208 having a vertical support 210 and a brace 212. The lower edge of the mold 203 and the building panel 204 are sufficiently close to thefloor line to contact wall base strips 214 permanently attached to the floor and which serve as the base guide members of the apparatus 200 in a manner similar to the base guide members 33 and 34 of FIG. 1A. The support structure is fitted with a vertical lifting mechanism 216 supporting a bridging frame 218 having an outer mold assembly 220 mounted at its lower end. The spacing between the faces of the inner mold 203 and outer mold 220 is established by the outer surfaces of the two base strips 214 and by fence accessories or/and previously established bay segments. The bay segment 201 is constructed by positioning the outer mold 220 at the base in abuttment with the outer strip 214 and pouring the construction material into the top of the cavity formed by the molds 203 and 220. The outer mold 220 is then retracted from contact with the construction material by means of the retraction device in the form of a pair of retraction cylinders 222 and 224 joined to the mold 220. Control of said cylinders 222 and 224 retracts the mold 220. The outer mold 220 is successively relocated in a series of vertically overlapping positions to establish the wall bay 201. After completion of the bay segment 201, the mold 220 may be raised further above the bay segment 201 to permit relocation and establishing the next bay segment on the next wall. Adjacent wall panel edges are mutually attached by a batten strip (not shown) which overlaps the intersection of the panel edges and is fastened to both of the adjacent panels to establish the integrity of the wall panelling as a structural skin. It may be apparent that the wall panelling can also be omitted. It may also be apparent that the structure 200 can be guided by base guide tracks rather than by location against the base strips 214 and that the bridging frame 218 can be mounted to either side of the lifting mechanism 216 rather than at the top of the structure.

, FIG. 7 is a further mold apparatus embodiment, of the present invention and referred to by the general reference character 250. The apparatus 250 is adapted for the construction of vertical interior walls 252 with wall panels or skins 254 and 256 on both faces of the wall. The apparatus 250 includes various elements similar to those of FIG. 6 and carry the same reference numeral distinguished by a prime designation. The panels 254 and 256 are spaced by means of the strips 214. The lifting or telescoping mechanism 216' includes a pair of spaced mold members 258 and 260 both of which are engaged to the mechanism and are guided over the surface of the panels 254 an 256 responsive to raising of the mechanism 216. The mold members 258 and 260 may be in the form of a pair of belt members to permit traversing over the panel surfaces without damage to the panel surface during the expansion and hardening of the constructing material. Constructing material is dispensed by means ofa foam dispensing gun 262. The dispensing gun 262 is attached to a vertical support member 263 mounted to a traversing head mechanism 264 on a track 266 of the bridging frame 216. The vertical position of the dispensing gun 262 is fixed in relation to the roller belt assemblies 258 and 260. As the construction material is dispensed the bridging frame 218 and the gun 262 is incremently raised with each traversing cycle of the dispensing gun 262 across the rail 266. Suitable controls may be fitted to the apparatus for the control of the dispensing gun 262 and the raising of the bridging frame 216. The traversing head mechanism 264 may also be supported from either side of the lifting mechanism 216 by a connecting member positioning the traversing head mechanism between the inner and outer skin panels in proximity to the vertical position of the roller belt assemblies 258 and 260.

FIG. 8 illustrates a molding apparatus referred to by the general reference character 300, for establishing roofing and/or ceilings in sequential steps. The molding apparatus 300 includes a pair of base support columns 302 and 304 joined to a base member 306. The columns 302 and 304 are joined to a base member 306. The columns 302 and 304 respectfully carry telescoping arms 308 and 310. The arms 308 is engaged to an arcuate mold face support member 312 adapted to control the pitch of the ceiling bay segments. A mold face, which may be in the form of a skin 314 is supported at the end of the arm 304 and member 312. Rafters 316 may be used and rested on the top surface of the mold face or on vertical walls. A roof overhang 318 may be engaged to the rafters 316 and an edging strip 320 fastened to the ends. A ridge pole 322 may also be secured to the rafters. Foam is then applied in bay segments to bond to verticalwalls, roof framing and ceiling skins into one monolithic structure. In erecting the ceiling, the ceiling skin 314 is positioned by means of the molding apparatus 300. The support member 312 sets the skin 314 in the selected angular pitch with edges of the skin 314 resting on the top edge of the vertical wall skins. The rafters 316, if used, are then located on the skin panel. The roof overhang strip 320 may be fastened to the ends of the rafters 316. The roof overhang 318 may then be fastened to the rafters 316. The ridge 322 may then be located and secured in place. The urethane constructing material 2 may then be sprayed.

I claim:

1. Apparatus for the construction of monolithic building structures of a select geometric pattern over a base member, said apparatus comprising:

a molding apparatus having a molding surface member with an exterior face of a contour shaped to conform to the desired shape of a bay wall segment of a building structure, said molding surface member being adapted to receive a volume supply of atomized urethane construction material and to contour the shape of said supply to conform to the surface of said molding surface member, support column members engaged to said molding surface member to support said molding surface member over a building base member; first positioning means engaged to the support column members for supporting said molding surface member in stationary lateral positions along a desired lateral path conforming to the desired lateral geometric pattern of the wall structure of said building, said first positioning means being laterally movable over said base member in incremental steps to permit said molding surface member to be incrementally laterally positioned relative to said base member; said positioning means engaged to the support column members for incrementally positioning said molding surface member in stationary elevated positions in steps relative to and over said base member along a desired elevated path conforming to the desired elevated geometric pattern of the wall structure of said building at each lateral position;

container means for storing a supply of liquid urethane construction material; and

applicator means engaged to said container means for receiving said urethane material and applying said liquid urethane construction material against said molding surface member from a location laterally relative to said molding surface member, said applicator means being adapted to direct said urethane material in abuttment with said exterior face of said molding surface member while said molding surface member is retained stationary in each lateral and elevated position, said applicator means including pressure pump means for pumping said liquid urethane material from said container means to the applicator means under pressure and atomizing said material as it is released from saidapplicator means toward said molding surface member.

2. The apparatus of claim 1 in which the applicator means includes a dispensing spray gun for receiving said pressurized liquid construction material from said container, said gun being disengaged from said molding apparatus and adapted to be positionally controlled relative to said exterior face of said molding surface member to permit said construction material to be applied against said exterior face in lateral layers.

3. The apparatus of claim 2 in which the positioning means of the mold apparatus includes a first guide means for guiding the elevational position of the molding surface relative to said base member adjacent a geometric path duplicating the desired elevational pattern of the building structure at each lateral position.

4. The apparatus of claim 3 in which the mold apparatus is adapted to support a skin material in abuttment with the exterior surface of the molding member, said skin material being adapted to adhere to said constructing material.

5. The apparatus of claim 3 in which the mold apparatus includes a second guide means for guiding said support column members laterally along said geometric path.

6. The apparatus of claim 5 in which the support columns include an elongated radial arm anchored at one end to a pivot and engaged adjacent the other terminal end to said molding surface member to guide said surface member in an arcuate elevated path corresponding to the desired path of the pattern of said desired building structure.

7. The apparatus of claim 6 in which the mold apparatus includes a lateral guide track means positioned about said base member for engaging said elongated arm about said one end and laterally guiding the pivot of said arm along said base member.

8. The apparatus of claim 7 in which the molding apparatus includes at least two molding surface members engages at an angle relative to one another and adapted to simultaneously conform to the desired shape of at least two different abutting bay wall segments of the building structure.

9. The apparatus of claim 7 in which the molding apparatus includes supplement mold members engaged about the exterior face of the molding surface member to support window casings adjacent said molding surface member.

10. The apparatus of claim 7 in which said guide track means includes a plurality of lateral guide tracks for engaging said elongated arm about the pivot of said arm and laterally guiding said arm pivot about a plurality of different paths along said base member.

11. The apparatus of claim 3 in which the exterior face of said molding surface member includes a design duplicating the desired surface design of bay wall segments of the desired building structure.

12. The apparatus of claim 4 in which the mold apparatus supports a skin material dispensing means for supporting a supply of flexible skin material, said dispensing means being adapted to dispense a supply of skin material in steps coinciding with the repositioning of the mold apparatus.

13. The apparatus of claim 3 in which the mold apparatus includes buttresses adapted to be positioned in abuttment with said exterior face of the molding surface member. 

1. Apparatus for the construction of monolithic building structures of a select geometric pattern over a base member, said apparatus comprising: a molding apparatus having a molding surface member with an exterior face of a contour shaped to conform to the desired shape of a bay wall segment of a building structure, said molding surface member being adapted to receive a volume supply of atomized urethane construction material and to contour the shape of said supply to conform to the surface of said molding surface member, support column members engaged to said molding surface member to support said molding surface member over a building base member; first positioning means engaged to the support column members for supporting said molding surface member in stationary lateral positions along a desired lateral path conforming to the desired lateral geometric pattern of the wall structure of said building, said first positioning means being laterally movable over said base member in incremental steps to permit said molding surface member to be incrementally laterally positioned relative to said base member; said positioning means engaged to the support column members for incrementally positioning said molding surface member in stationary elevated positions in steps relative to and over said base member along a desired elevated path conforming to the desired elevated geometric pattern of the wall structure of said building at each lateral position; container means for storing a supply of liquid urethane construction material; and applicator means engaged to said container means for receiving said urethane material and applying said liquid urethane construction material against said molding surface member from a location laterally relative to said molding suRface member, said applicator means being adapted to direct said urethane material in abuttment with said exterior face of said molding surface member while said molding surface member is retained stationary in each lateral and elevated position, said applicator means including pressure pump means for pumping said liquid urethane material from said container means to the applicator means under pressure and atomizing said material as it is released from said applicator means toward said molding surface member.
 2. The apparatus of claim 1 in which the applicator means includes a dispensing spray gun for receiving said pressurized liquid construction material from said container, said gun being disengaged from said molding apparatus and adapted to be positionally controlled relative to said exterior face of said molding surface member to permit said construction material to be applied against said exterior face in lateral layers.
 3. The apparatus of claim 2 in which the positioning means of the mold apparatus includes a first guide means for guiding the elevational position of the molding surface relative to said base member adjacent a geometric path duplicating the desired elevational pattern of the building structure at each lateral position.
 4. The apparatus of claim 3 in which the mold apparatus is adapted to support a skin material in abuttment with the exterior surface of the molding member, said skin material being adapted to adhere to said constructing material.
 5. The apparatus of claim 3 in which the mold apparatus includes a second guide means for guiding said support column members laterally along said geometric path.
 6. The apparatus of claim 5 in which the support columns include an elongated radial arm anchored at one end to a pivot and engaged adjacent the other terminal end to said molding surface member to guide said surface member in an arcuate elevated path corresponding to the desired path of the pattern of said desired building structure.
 7. The apparatus of claim 6 in which the mold apparatus includes a lateral guide track means positioned about said base member for engaging said elongated arm about said one end and laterally guiding the pivot of said arm along said base member.
 8. The apparatus of claim 7 in which the molding apparatus includes at least two molding surface members engaged at an angle relative to one another and adapted to simultaneously conform to the desired shape of at least two different abutting bay wall segments of the building structure.
 9. The apparatus of claim 7 in which the molding apparatus includes supplement mold members engaged about the exterior face of the molding surface member to support window casings adjacent said molding surface member.
 10. The apparatus of claim 7 in which said guide track means includes a plurality of lateral guide tracks for engaging said elongated arm about the pivot of said arm and laterally guiding said arm pivot about a plurality of different paths along said base member.
 11. The apparatus of claim 3 in which the exterior face of said molding surface member includes a design duplicating the desired surface design of bay wall segments of the desired building structure.
 12. The apparatus of claim 4 in which the mold apparatus supports a skin material dispensing means for supporting a supply of flexible skin material, said dispensing means being adapted to dispense a supply of skin material in steps coinciding with the repositioning of the mold apparatus.
 13. The apparatus of claim 3 in which the mold apparatus includes buttresses adapted to be positioned in abuttment with said exterior face of the molding surface member. 